Automated rubber molding and de-molding

ABSTRACT

Molded rubber objects may be molded and de-molded by defining both a desired final form for the molded rubber object and a tab extending from the final form of the molded rubber object using a cavity in a mold. Rubber pellets may be dispensed in predetermined amounts at desired location(s) within the cavity to provide the rubber needed to form the molded rubber object. Heat and pressure may be applied to the mold to cause the rubber pellets to fill the cavity defining both the desired final form of the molded rubber object and the tab. After the heat and pressure has been applied, a gripping device may grasp the tab and move the tab in a direction and with sufficient force to peel the rubber object from the mold cavity. If desired, the tab may be removed from the molded rubber object.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

TECHNICAL FIELD

The present invention relates to the processing of rubber. Moreparticularly, the present application relates to systems and methods forthe automated molding and de-molding of rubber parts, particularly partsfor use in shoe production.

BACKGROUND

The rubber used to form shoe parts, such as shoe outsoles, hastraditionally been prepared from sheets of rubber cut to an approximatesize and shape and then molded to cure the rubber part into somethingclose to its final desired form.

SUMMARY

Aspects of the present invention provide systems and methods for theautomated fabrication of rubber components for products such as shoes.In systems and methods in accordance with aspects of the presentinvention, a mold may be provided having a cavity therein that definesthe approximate desired final form of the desired rubber part, such asthe rubber part's desired shape and size, as well as any textures,contours, or other surface variations desired in the final rubber part.The cavity may further define at least one tab extending from thedesired final form of the rubber part. Such a tab may extend from anyportion of the cavity that defines the desired final form of the moldedpart, and thereby create a tab extending from the resulting moldedrubber object at any portion. The cavity and/or tab may be formed in oneor more portions of a mold, for example in the mold bottom, in a moldtop, in both the top and bottom of a mold, in intermediate layers of amold, lateral portion(s) of a mold, etc. A tab may extend in a varietyof angles, orientations, etc. relative to the cavity defining thedesired rubber part and/or the mold defining the cavity. For example, arubber part formed in accordance with aspects of the present inventionmay extend in a substantially planar co-planar fashion, at an acuteangle, at a perpendicular angle, or at an obtuse angle relative to thesubstantially planar part. In particular examples, the cavity may definea desired final form having an elongated shape and the at least one tabmay be positioned at or near one end of the elongated form. For example,an elongated form for a rubber molded object may be useful for creatinga rubber part such as a shoe outsole.

Regardless as to the shape of the final form of the rubber objectdefined by the cavity, a tab may extend from a portion of the mold wheretwo mold portions are contact each other in the molding process, whichoften correspond to a portion of the molded rubber object with “flash”i.e., excess rubber attached to the rubber object that forms betweenadjacent portions of a mold during the application of heat and/orpressure in the molding process. By locating a tab in a portion of thepart that is likely to have flash associated with it, the tab may beremoved from the molded rubber part at the same time and in the samemanner in which the part is de-flashed.

The cavity that defines the final form of the desired part and at leastone tab extending from the final form of the desired part may beaccessible by removing a mold top from mold bottom. The mold top, themold bottom, and any further portions of a mold, may be partially orentirely separable to permit access to the cavity. For example, a hingeor other movable connection between a mold top and bottom may beprovided to permit the mold to be partially separated to permit accessto the cavity defining the desired rubber part.

A dispenser may dispense rubber pellets within the cavity of the mold.The dispenser may be movably positioned at a first positioncorresponding to a first location within the cavity. At the firstlocation, the dispenser may dispense a predetermined amount of rubberpellets into the cavity. Thereafter, the dispenser may optionally bemoved to a second position corresponding to a second location within thecavity. At the second position, the dispenser may dispense a secondpredetermined amount of rubber pellets. The dispensing of rubber pelletsoptionally may be repeated at any number of locations within one or morecavities contained within a mold in accordance with aspects of thepresent invention. The amount of rubber pellets dispensed at a firstlocation, a second location, or any other locations within one or morecavities in accordance with aspects of the present invention may be thesame or different at the various locations. Different amounts of rubberpellets may be desired at different locations within a cavity due to theshape of a rubber object requiring differing volumes of rubber fordifferent portions of a rubber object. For example, a forefoot portionof a shoe outsole may require more rubber than a heel portion of a shoeoutsole and, therefore, a larger amount of rubber may be dispensed atthe forefoot location than the heel location of a cavity. Thepredetermined amount of rubber pellets dispensed at any given locationmay be determined by weight, volume, the time devoted to dispensing, orany other means. In one aspect, it can be preferable to dispense pelletsaccording to their weight. A dispenser may be positioned using an X-Ytable, a six-axis robotic arm, or any other mechanism.

After all desired rubber pellets have been dispensed at the appropriatelocations within one or more cavities of a mold, the mold may be closed.Heat and/or pressure may be applied to the mold to cause the rubberpellets within the cavity or cavities to fill the cavity that definesthe approximate final desired shape of the rubber object and at leastone tab extending from the object. After a predetermined amount of timehas elapsed, the mold may be opened to facilitate the removal of themolded rubber object, for example, by separating the mold top from themold bottom.

After the mold has been opened, a gripping device may be positioned overthe tab of a rubber object. A gripping device may be positioned using,for example, a six-axis arm to place the gripping device at a locationcorresponding to the tab formed as part of the molded rubber object. Thegripping device may then be used to grip the tab. After gripping the tabextending from the rubber object, the gripping device may be moved awayfrom the mold bottom in a direction that is not perpendicular to, andalso not parallel to, the mold bottom. In this manner, the grippingdevice may use the tab to “peel” the rubber object out of the cavity.The tab may be subsequently removed from the rubber object usingscissors, a shear, a knife, and/or as part of a standard de-flashingprocess. Alternatively, a tab may be utilized as part of an objectformed using the rubber object.

DRAWINGS

The present invention is described in detail below with reference to theattached drawing figures, wherein:

FIG. 1-5 schematically illustrates an example of a system in accordancewith aspects of the present invention;

FIGS. 6-7 illustrate examples of an X-Y table used to position a rubberpellet dispenser relative to an exemplary mold;

FIGS. 8-9 illustrate an exemplary rubber pellet dispenser;

FIGS. 10-12 illustrate an exemplary mold and heat press;

FIGS. 13-16 illustrate examples of a gripping device and arm for use inremoving a rubber object from a mold;

FIGS. 17-25 illustrate examples of various orientations and locations oftabs relative to a rubber object;

FIGS. 26-32 illustrate examples of molds that may be used to form tabswith various orientations and locations relative to a rubber object;

FIG. 33 illustrates an example of a method in accordance with aspects ofthe present invention;

FIG. 34 illustrates a schematic diagram of an example system inaccordance with aspects of the present invention;

FIG. 35 illustrates a top view of an example of an open mold suitablefor use in accordance with aspects of the present invention;

FIG. 36 illustrates a side view of an example mold suitable for use inaccordance with aspects of the present invention;

FIG. 37 illustrates a side view of an example of a closed mold suitablefor use in accordance with aspects of the present invention;

FIG. 38 illustrates a side view of an example of a mold suitable for usein accordance with aspects of the present invention while heat andpressure is applied to the mold;

FIG. 39 illustrates a side view of an example of a mold suitable for usein accordance with aspects of the present invention being opened;

FIG. 40 illustrates a top view of an example of an open mold suitablefor use in accordance with aspects of the present invention;

FIG. 41 illustrates an example of a gripping device positioned to removea rubber object from a mold in accordance with aspects of the presentinvention;

FIG. 42 illustrates an example of a gripping device removing a rubberobject from a mold in accordance with aspects of the present invention;

FIG. 43 illustrates an example of a gripping device removing a rubberobject from a mold in accordance with aspects of the present invention;

FIG. 44 illustrates an example of a rubber object that has been removedfrom a mold in accordance with aspects of the present invention by agripping device;

FIG. 45 illustrates examples of rubber objects after they have beenremoved from a mold in accordance with aspects of the present invention;

FIG. 46 illustrates an example of the removal of a tab from a rubberobject in accordance with aspects of the present invention;

FIG. 47 illustrates an example of a rubber object after a tab has beenremoved from it in accordance with aspects of the present invention;

FIG. 48 illustrates examples of rubber objects after tabs have beenremoved from them in accordance with aspects of the present invention;

FIG. 49 illustrates an example of a mechanical arm, a dispenser, and agripping device in accordance with aspects of the present invention; and

FIGS. 50-58 illustrate coordinated movements within a molding andde-molding system in accordance with aspects of the present invention.

DETAILED DESCRIPTION

The present invention provides systems and methods for fabricatingrubber parts, particularly for use in shoe production. The systems andmethods may form rubber objects, such as parts for incorporation into aproduct. Aspects of the present invention may utilize a mold with acavity that defines the size and shape of a desired part, and thatfurther provides at least one gap that defines a tab extending from thedesired part. A mold may be designed such that a tab extends from aportion of a part, such as the perimeter of the part corresponding tothe junction of mold components, which will likely have flash aroundthat edge. For example, a cavity corresponding to a desired tab may beprovided in one or more portions of a mold at or near where the faces oftwo or more mold portions (e.g., a top and a base) meet when closed,although a cavity to form a tab may be located anywhere within a cavityand the ultimate molded rubber object. For example, a tab may beoriented partially or entirely within the interior of an object.Further, more than one cavity to form a tab may be provided in a moldcavity to produce more than one tab on the corresponding molded object,in which case different tabs may be located differently relative to themolded object formed.

A tab extending from a molded rubber object may be substantially lessthick than the rubber object molded. For example, the tab extending fromthe molded rubber object may be no more than 20% the thickness of themolded rubber object itself, or even no more than 10% the thickness ofthe molded rubber object itself. While different rubber formulations anddifferent molded part forms will have different properties, a tab may besufficiently thick to resist breaking or tearing when used to peel themolded rubber object from the cavity after molding while beingsufficiently thin to be easily removed from the molded rubber object ifremoval of the tab is desired. Further, a tab thickness may be minimizedto reduce material usage while also being thick enough to allow rubberto enter into the cavity defining the tab under heat and/or pressure. Atab may extend at any angle relative to a molded rubber object at whichthe tab may be grabbed by a gripper used to remove the molded rubberobject from the mold. Generally, the tab may protrude perpendicularlyfrom the part of the molded rubber object to which the tab is adjacent.In some examples, a tab may extend substantially perpendicular to thetop surface of a molded rubber object, but other angles may be used fortabs, and rubber objects formed need not have planar top surfaces. Thelength of a tab extending from a molded rubber object may vary, forexample, based upon the size of any gripping device that will be used togrip the tab as part of the de-molding process for the molded rubberobject.

Referring now to FIG. 1, a rubber molding and de-molding system 100 forthe automated molding of rubber parts is illustrated in a perspectiveview. The system 100 comprises two banks of molding stations served by arubber dispensing station 126. The rubber dispensing station 126 movesalong the rail 120 to dispense rubber pellets from the hopper 124 intomolds associated with each of the molding stations. Further, it iscontemplated that one or more portions of the dispensing station 126 mayalso move vertically and laterally (away from and toward the rail 120)to deposit rubber pellets in various portions of the different molds.The molding stations shown include molding station 102, molding station104, molding station 106, molding station 108, molding station 111,molding station 113, molding station 114, and molding station 116. Themolding stations may each have the same mold or different molds. Forexample, each molding station could have a mold for the outsole of thesame model shoe but a different size. The function of an exemplarymolding station will be illustrated in more detail subsequently.

The system also comprises a mechanical arm 132 that removes the curedrubber objects 140 and 142 from the molding stations and places them onconveyance mechanism 160. Conveyance mechanism 160 carries the curedrubber objects 140 and 142 to a subsequent process (e.g., packaging,assembly, buffing, deflashing). The conveyance mechanism 160 maycomprise a conveyor belt, a system of pushers and rollers, a chain orbelt drive system. The mechanical arm 132 moves along rail 130 to accesseach of the molding stations.

Turning now to FIG. 2, a close-up view of the dispensing station 126 andan exemplary molding station 108 is shown in a perspective view, inaccordance with an aspect of the present invention. A mold bottom 110may provide at least one cavity 112 corresponding to the approximatedesired size and shape of a finished molded part. The mold bottom 110may sit on a lower portion 170 of a heat press that is part of themolding station 108. The mold bottom 110 and lower portion 170 may slideout from the interior of the molding station 108 on tray apparatus 138to receive rubber pellets from the dispenser 122.

The dispensing station 126 may dispense predetermined amounts of rubberpellets into a cavity 112 within the mold bottom 110 after the moldbottom 110 is in position under the dispenser. The dispenser 122 may bepositionable in at least two dimensions at dispensing station 126.Dispenser 122 may be positionable using mechanisms such as an X-Y table,a mechanical arm, or other mechanisms. Further, it is contemplated thatthe dispensing station 126 is adapted to move one or more portionsvertically (i.e., up and down). For example, the dispenser 122 may bemoveably coupled such that an actuator may raise and lower a position ofthe dispenser 122 relative to a mold to facilitate effective deposit ofrubber pellets in the molds.

Rubber pellets dispensed by dispenser 122 at dispensing station 126 maycomprise uncured or partially cured pieces of rubber that are eachsubstantially smaller than the cavity 112 used for molding. Rubberpellets may be spherical, cylindrical, cubical, rectangular, irregular,or any other shape. Rubber pellets may be formed through processes suchas cutting, extrusion, etc. Anti-tack materials, in powder, liquid, orother form, may be incorporated as part of the rubber pellets dispensedat dispensing station 126. Dispensing station 126 may either contain oroperably connect to a reservoir (not shown) that provides a supply ofrubber pellets to the hopper 124. The hopper 124 is connected to thedispenser 122 in a manner that allows rubber pellets to pass from thehopper 124 to the dispenser 122. Once the rubber pellets have beendispensed, the mold bottom 110 and the lower portion 170 slide back intoa mold opening within the molding station 108.

Turning now to FIG. 3, a perspective view of open molding station 108 isshown. After a predetermined amount of rubber pellets 133 has beendispensed by dispenser 122 into a cavity 112 of the mold bottom 110, thebottom may be returned to the mold opening 194 within molding station108. The mold opening 194 is part of the heat press 192 within themolding station 108. 133

FIG. 4 shows a perspective view of a closed molding station 108. Asshown in FIG. 4, the mold apparatus 117 (alternatively described as themold) can be closed when the mold top 115 is brought together with themold bottom 110. The molding station 108 may provide heat and/orpressure to liquefy and cure rubber pellets dispensed within the moldapparatus 117. The heat may be applied by heat press 192. Heat press 192comprises an upper portion 162 and a lower portion 170, both of whichmay comprise heat elements. As explained in examples below, moldingstation 108 may further comprise machinery or equipment that closes amold by, for example, applying a mold top to a mold bottom for theapplication of heat and/or pressure by a heat press or other means.

FIG. 5 shows a perspective view of the rubber objects 140 and 142 beingremoved from the mold bottom 110. After molding station 108 has applieda predetermined amount of heat and/or pressure for a predeterminedamount of time (or until a desired observed condition such as internalmold temperature has been met), the mold apparatus 117 opens andgrippers 180 and 182 attached to the mechanical arm 132 remove the curedrubber objects 140 and 142, as shown in FIG. 5. The gripping device canengage a tab formed in a molded rubber object for purposes of de-moldingthe finished rubber object.

After a rubber object has been removed from the mold bottom 110, atrimming and/or de-flashing station 150 may remove any undesirable flashfrom the molded rubber object and/or remove the tab used by the grippers180 and 182 to remove the rubber object from the mold bottom 110. Tabremoval and de-flashing may be alternatively performed at differentstations or, in other alternatives, omitted. Further examples of ade-flashing and/or trimming station 150 are described in examples below.

The operation of the various components of system 100 may be controlledby a computing device 190 operating via a connection to the variouscomponents described herein. For example, computing device 190 maycontrol the operation of the molding stations, the dispensing of rubberpellets at dispensing station 126, the amount of pressure, heat, orother parameters applied at molding stations, the de-molding operations,any de-flashing/trimming operations at trimming stations, cleaning andmold preparation operations, etc. Computing device 190 may comprise oneor multiple computing devices with processing units and digital memoryexecuting computer-readable code to cause system 100 or other systems inaccordance with the present invention to perform their operations inaccordance with the present invention.

Referring now to FIG. 6, a top view of an exemplary dispenser 122 isillustrated. The dispenser 122 utilizes an X-Y table 605 to movedispensing cups 622 and 624 in two dimensions to position the cups 622and 624 at one or more desired locations over cavity 112 of mold bottom110 for the dispensing of rubber pellets. Other dispensing stations maybe used in accordance with aspects of the present invention, such asdispensers mounted on articulated mechanical arms, dispensers rigidlyaffixed at a given location that permit the mold bottom 110 to bepositioned at one or more desired locations beneath the dispenser 122,etc.

FIGS. 50-58 use a perspective view of part of system 100 illustratedcoordinated actions of components within system 100. Initially, FIG. 50shows molding station 108 and molding station 106 in an open positionready to receive pellets. The components of molding station 108 havebeen described above and the components of molding station 106 aresimilar. The components of molding station 106 comprise a mold bottom110, having cavity 113. The mold bottom 110 is resting on lower portion171 of a heat press. The lower portion 171 slides in and out of themolding station 106 on tray apparatus 139.

Turning now to FIG. 51, a dispensing operation is illustrated. As can beseen, the dispensing station 126 has moved adjacent to molding station106. The dispensing station dispenses rubber pellets 133 within a cavity113.

Turning now to FIG. 52, the transition of molding station to the closedposition is illustrated. As can be seen, the lower portion 171 and themold bottom 196 have been withdrawn into the molding station 106. Themold top 165 has been placed on the mold bottom 196 to enclose cavity113. The upper portion 164 can apply pressure and heat to the closedmold formed from mold bottom 196 and mold top 165. The components ofmolding station 108 remaining in the open position ready to receivepellets. The dispenser 122 on the dispensing station 126 has been raisedin preparation for movement to molding station 108. In one aspect,dispensing cups (not shown) within the dispenser 122 are prefilled atthis point in preparation for dispensing pellets once the dispensingstation 126 arrives at the molding station 108.

Turning now to FIG. 53, the dispensing operation is illustrated withreference to molding station 108. Molding station 106 remains in theclosed position. Molding station 106 may remain in the closed positionfor a duration sufficient to vulcanize the rubber pellets 133 with thecavity 112, for example five minutes. As can be seen, dispenser 122 haslowered to a dispensing position over cavity 112 and has dispensedpellets 135 in at least two different locations. Stated differently, inaddition to being positionable in both the X and Y coordinates, thedispenser may also be moved vertically to raise and lower into anappropriate position for depositing rubber pellets in a mold.

Turning now to FIG. 54, the transition of molding station 108 to theclosed position is illustrated. As can be seen, the lower portion 170and the mold bottom 110 have been withdrawn into the molding station108. The mold top 115 has been placed on the mold bottom 110 enclosingcavity 112. Upper portion 162 can apply heat and pressure to the closedmold formed by mold bottom 110 and mold top 115.

Turning now to FIG. 55, the opening of molding station 106 inpreparation for removal of a molded rubber object is illustrated. Moldbottom 196 and lower portion 171 have been extended out from moldingstation 106. As can be seen, mold bottom 196 contains molded rubberobjects 141 and 143.

Turning now to FIG. 56, the removal of molded rubber objects isillustrated. Arm 132 has moved to a position on rail 130 across from themolding station 106. The grippers 180 and 182 grab portions of moldedrubber objects 141 and 143 respectively. In one aspect, the grippers 180and 182 grab removable tabs molded with molded objects 141 and 143. Ascan be seen, molding station 108 remains in a closed position. It iscontemplated that the dispensing station may move into a position todispense rubber pellets 133 within the cavity 113 at this point in thesequence if the dispensing station is available. However, it iscontemplated that the molding station 108 may remain in the open andprepared state for a period of time until the dispensing station isavailable to provide pellets.

Turning now to FIG. 57, the opening of molding station 108 inpreparation for removal of a molded rubber object is illustrated. Moldbottom 110 and lower portion 170 have been extended out from moldingstation 108. As can be seen, mold bottom 110 contains molded rubberobjects 140 and 142. The grippers 180 and 182 are empty, havingpreviously deposited molded objects 141 and 143 on conveyance mechanism160.

Turning now to FIG. 58, the removal of molded rubber objects frommolding station 108 is illustrated. The arm 132 has moved down rail 130to a location across from molding station 108. Grippers 180 and 182 havegripped molded rubber objects 140 and 142. In one aspect, the grippers180 and 182 grab removable tabs molded with molded objects 140 and 142.As can be seen, molding station 106 remains in an open position readyfor cooling, cleaning, preparation, and eventually the receipt of morepellets to repeat the molding process.

In the example illustrated in FIG. 6, dispensing cup 622 may movelaterally in a first direction 642 along a first arm 620 of the X-Ytable 605. Dispensing cup 624 may move in a similar fashion. Meanwhile,first arm 620 may be moved orthogonally to the first direction 642 insecond direction 632. Arm 620 may slide along a perpendicular arm 610 topermit dispensing cups 622 and 624 to be positioned at a variety oflocations.

Referring now to FIG. 7, a top view of the dispenser 122, such asillustrated in FIG. 6, is illustrated after dispensing cups 622 and 624have been moved to a first location 720 and second location 740 over acavity 112. By moving dispenser dispensing cups 622 and 624 in thesecond direction 632, dispensing cups 622 and 624 may subsequently bepositioned at a third location 710 and fourth location 730. In general,the dispenser may permit the dispensing cups 622 and 624 to dispense oneor more predetermined amounts of rubber pellets at one or more locationswithin one or more cavities 112 of the mold bottom 110. As describedfurther in some examples herein, dispensing cups 622 and 624 may beprovided with a supply of rubber pellets to dispense in predeterminedamounts at locations within at least one cavity 112 provided in the moldbottom 110, such as the first location 720, the second location 740, thethird location 710, and/or the fourth location 730. Alternatively,pellets may be distributed throughout the mold, rather than dispensed inlocations. The amount of rubber pellets dispensed at a given locationmay be the same as the amounts dispensed at other locations.Alternatively, the amount of rubber pellets dispensed at variouslocations may differ. In one aspect, it can be preferable to dispensepellets according to their weight.

Referring now to FIG. 8, an example of a dispensing cup 622 isillustrated in cross section. Example dispensing cup 622 illustrated inFIG. 8 and subsequently in FIG. 9 is illustrative only, and other typesand configurations of cups may be used in accordance with aspects of thepresent invention. As shown in the example of FIG. 8, dispensing cup 622comprises a substantially funnel-shaped housing 814 retaining therein aplurality of rubber pellets 820. The funnel-shaped housing 814 isbi-furcated by divider 815, creating two separate chambers 817 and 819within housing 814. Rubber pellets 820 are maintained within dispensingcup 622 by movable flange 810. Flange 810 may be disposed laterally asindicated by arrows 812 to open and close dispensing cup 622 to permitthe dispensing of a predetermined amount of rubber pellets 820. Thepredetermined amount may be determined by weight.

In one aspect, the flange 810 opens halfway to allow chamber 819 todispense pellets in a first location and then opens fully to allowchamber 817 to dispense pellets at a second location. The dispensing cup622 may retain or receive amounts of rubber pellets 820 that have beenpreviously measured by volume, weight, or other means to provide adesired predetermined amount. In one aspect, it can be preferable todispense pellets according to their weight. The amount of rubber pellets820 dispensed by dispensing cup 622 at a given predetermined locationmay be determined, for example, by the length of time flange 810 hasbeen opened. Alternatively/additionally, a dispensing cup 622 may usequantities such as volume, weight, etc. rather than time measurements asrubber pellets 820 are dispensed to provide a predetermined amount ofrubber pellets at a predetermined location. In one aspect, theappropriate amount of pellets for a location is measured into a chamberand the chamber is then emptied when the dispensing cup 622 is at thelocation. Thus, in one aspect, the dispensing cup 622 empties the entirechamber at a location.

Referring now to FIG. 9, the cross-section view shows that dispensingcup 622 has dispensed an amount 910 of rubber pellets 820 while flange810 has been moved laterally to open dispensing cup 622 halfway. Flange810 may be returned to a closed position (as illustrated in FIG. 8)after the amount 910 of rubber pellets 820 dispensed corresponds to adesired predetermined amount of rubber pellets 820. While flange 810 isillustrated herein at the terminal end of dispensing cup 622, flange 810may be located within a dispensing cup 622 and/or may comprise multipleflanges or pieces that may be actuated to release rubber pellets 820from dispensing cup 622. Further, one or more flange 810 may be actuatedby hinging, sliding, or other movements other than lateral movement asshown in the present example. Though not shown, the dispensing cup 622may include vibrators, thumpers, augurs, or another apparatus tofacilitate the rubber's exit from the dispensing cup 622.

Referring now to FIGS. 10-12, an exemplary heat press station 1000 isillustrated. Heat press station 1000 may be part of a molding station(e.g., heat press station 141 within molding station 108) or standseparately. The mold illustrated previously comprising mold bottom 110and mold top 115 is used with FIGS. 10-12, but other molds could be usedin different aspects. As illustrated in FIG. 10, a side view of the moldbottom 110 having a cavity 112 is illustrated. A first predeterminedamount of pellets 1061 has been dispensed at a first location withincavity 112, and a second predetermined amount of rubber pellets 1062 hasbeen dispensed at a second location within cavity 112. A mold top 115for the mold bottom 110 with a tab form 1014 component has beenprovided. Mold top 115 and the mold bottom 110 may be closed asindicated by arrow 1070 to enclose pellets 1061, 1062 within cavity 112.It should be noted that cavity 112 and the tab form 1014 componentprovided are for illustrative purposes only in FIG. 10. Some examples ofdifferent tab form 1014 orientations are further described below forillustrative purposes. A base portion 1010 of a heat press may receiveand retain the mold bottom 110. A heating element 1020 may generate heatfor application to the mold assembly and, subsequently, pellets 1061,1062 within cavity 112.

The heat press may further comprise a top portion 1030 with a heatingelement 1040 provided therein. Top portion 1030 may be actuated asindicated by arrow 1052 by a piston 1050 to apply pressure to the moldtop 115, the mold bottom 110, base portion 1010, and ultimately pellets1061, 1062 within cavity 112 as desired. The application of heat and/orpressure may accordingly cause the pellets 1061, 1062 to entirely orpartially liquefy and spread through cavity 112.

Referring now to FIG. 11, a cross-section of the heat press station 1000is shown. Top portion 1030 of the heat press has been applied by piston1050 to apply pressure to the closed mold assembly in conjunction withbase portion 1010. Under the application of heat and pressure, thepellets 1061, 1062 illustrated in FIG. 10 have filled the cavity 112 andthe associated tab form 1014. In this manner, a rubber object 1160conforming in size and shape to the cavity 112 and tab form 1014 may beformed.

A flash channel can be provided around the exterior of the cavity at apoint where the mold top 115 and the mold bottom 110 come together toform cavity 112. The flash channel is visible at the left end 1132 andthe right end 1134 of the flash channel. The flash channel may extend afew millimeters from the cavity. The flash channel allows excess rubberto flow from the cavity. The resulting flash can be removed from theresulting object after the object is removed from the mold.

FIG. 12 shows a side view that illustrates the separation of the topportion 1030 of the heat press station 1000 to permit the removal ofmold top 115 from the mold bottom 110. As illustrated in FIG. 12, therubber object 1160 produced as shown in FIG. 11 by the application ofheat and/or pressure has been allowed to at least partially solidifyinto a solid rubber object 1260. As can be seen in FIG. 12, rubberobject 1260 has taken the shape and form of cavity 112 and theassociated tab form 1014.

Referring now to FIG. 13, a side view of a gripping device 1360 isshown. The gripping device 1360 may be positioned over the tab 1310 ofthe rubber object 1260 while within mold bottom 110. Gripping device1360 may be positioned using a mechanical arm 1340. Mechanical arm 1340may carry gripping device 1360 at the terminal end 1342 of the arm 1340.A computing device may cause mechanical arm 1340 and gripping device1360 to engage the tab 1310 for removal.

As shown in FIG. 14, gripping device 1360 has used the tab 1310 ofrubber object 1260 to begin lifting rubber object 1260 from cavity 112.

FIG. 15 illustrates an example of gripping device 1360 having nearlyentirely extracted rubber object 1260 from cavity 112 by gripping tab1310 and moving in an oblique direction 1510 relative to mold bottom 110to effectively separate rubber object 1260 from mold bottom 110.

As shown in FIG. 16, a gripping device 1360 moved by mechanical arm 1340has fully removed rubber object 1260 from cavity 112 of mold bottom 110.The use of release agents or other mold treatments, and/or additives toa rubber mixture or the rubber pellet mixture may facilitate the removalof a formed rubber object 1260 from the cavity 112 of a mold bottom 110as described herein.

Referring now to FIG. 17, a side view of a rubber object that may beformed in accordance with aspects of the present invention isillustrated. Rubber object 1760 may have a tab 1710 extending upwards atan angle from the rubber object 1760. The tab 1710 may extend fromeither the flash 1790 or the rubber object 1760. The base portion ofrubber object 1760 may have a total thickness 1762, while tab 1710 mayhave a total thickness 1712. In one aspect, the tab is approximately 1to 1.5 mm thick and 3-5 mm long. Though not shown, the width can beapproximately 1 to 5 cm wide. The thickness 1712 of tab 1710 may be, forexample, approximately one-fifth the thickness 1762 of base portion orweb of rubber object 1760. As further illustrated in FIG. 17, rubberobject 1760 may possess flash 1790 corresponding to the junction pointof different portions of a mold in which rubber object 1760 was formed.For example, flash may form at the location of a rubber object 1760corresponding to the junction of mold bottom 110 and mold top 115, suchas described above.

Referring now to FIG. 18, a side view of a rubber object 1860 with a tab1810 extending therefrom is provided. The tab 1810 may extend fromeither the flash 1890 or the rubber object 1860. Once again, rubberobject 1860 may possess flash 1890 corresponding to the junction ofdifferent portions of a mold. The base portion of rubber object 1860 mayhave a thickness 1862, while tab 1810 may have a thickness 1812. Thethickness 1812 of tab 1810 may be, for example, one-tenth the thickness1862 of the base portion of rubber object 1860.

Referring now to FIG. 19, a side view of a rubber object 1960 having atab 1910 is provided. In the example of FIG. 19, tab 1910 is positionedwithin the perimeter of rubber object 1960 and terminates within theperimeter of the rubber object 1960. Once again, rubber object 1960possesses flash 1990 corresponding to the juncture of different portionsof the mold used to form rubber object 1960. Tab 1910 may have athickness 1912 that is a fraction of the thickness 1962 of base portionof rubber object 1960. For example, the ratio of the thickness 1912 oftab 1910 to the thickness 1962 of base portion of rubber object 1960 maybe 1:10, 1:5, etc.

Referring now to FIG. 20, a top view of a rubber object 2060 similar tothose shown from the side in FIG. 17 and/or FIG. 18 is illustrated. Asshown in FIG. 20, a tab 2010 may extend from the base portion of arubber object 2060 at a terminal end 2050 on the perimeter of the rubberobject 2060. The example illustrated in FIG. 20 affectively positionstab 2010 at the junction of the flash 2090 and the rubber object 2060,thereby potentially permitting tab 2010 to be removed from the rubberobject 2060 at the same time the flash 2090 is removed.

Referring now to FIG. 21, a top view of a rubber object, such as therubber object illustrated in side view in FIG. 19, is provided. In theexample of FIG. 21, tab 2110 extends from an interior location 2150 ofthe rubber object 2160. In the example of FIG. 21, tab 2110 is entirelycontained within the perimeter of the rubber object 2160. If tab 2110 isto be removed from the rubber object 2160, the removal of flash 2190 mayhave to comprise a separate process.

Referring now to FIG. 22, a top view of a rubber object 2260 similar tothose shown from the side in FIG. 17 and/or FIG. 18 is provided. Asshown in FIG. 22, a tab 2210 may extend from the flash 2290 at aterminal end 2250 of a rubber object 2260. Thus, in the example of FIG.22, the tab 2210 is attached to the flash 2290 rather than the perimeterof the rubber object 2260. Attaching the tab to the flash can allow fora thicker tab that is easy to grip while maintaining a thin base that iseasy to cut away from the rubber object 2260. The example illustrated inFIG. 22 affectively positions tab 2210 within flash 2290, therebypotentially permitting tab 2210 to be removed from the rubber object2260 at the same time flash 2290 is removed.

Referring now to FIG. 23, a side view of a rubber object 2360 with a tab2310 is provided. In the example of FIG. 23, a first plane 2330 roughlyparallel to the base portion of rubber object 2360 is shown. Tab 2310extends along a second plane 2340 at an angle 2350 substantiallyperpendicular to first plane 2330. In the example of FIG. 23, tab 2310may be formed in a mold top, such as mold top 115 illustrated anddescribed above. Flash 2390 is shown on the perimeter of the rubberobject 2360. As will be discussed herein, it is contemplated that a tabis formed as extending at least from the flashing. In an exemplaryaspect, it is contemplated that the tab is dependent on the flash for aphysical connection to the intended rubber object. As depicted in FIG.23, the tab 2310 is offset from a vertical portion (portionsubstantially parallel with plane 2340) of the rubber object 2360 suchthat when the flash 2390 is removed, the tab 2310 will no longer beaffixed with the rubber object 2360, in an exemplary aspect. It is alsocontemplated that a tab may be coupled directly to the intended rubberobject such that even after the flash is removed, the tab remainscoupled with the rubber object, in an exemplary aspect. Therefore, whilesome of the illustrated aspects show a particular relationship betweenthe rubber object, the flash, and the tab, it is contemplated that arelationship between the tab, rubber object, and flash may be altered toachieve aspects of the present invention provided herein. For example,at least FIGS. 23-32 depict a tab that may be illustrated in alternativerelative locations to the flash and rubber object.

Referring now to FIG. 24, a side view of a rubber object 2460 with a tab2410 is provided. A plane 2430 corresponding to rubber object 2460 isillustrated. Tab 2410 extends along a second plane 2440 at an angle 2450with first plane 2430. In the example of FIG. 24, angle 2450 is acute.The actual measure of angle 2450 may vary based upon, for example, thelimitations of a mold, the flowability of rubber used in accordance withaspects of the present invention, the limitations and/or needs of agripping device, etc. A rubber object with a tab 2410 extending asillustrated in FIG. 24 at angle 2450 may be formed, for example, byproviding for the formation of tab 2410 in a mold top. Flash 2490 isshown on the perimeter of the rubber object 2460.

Referring now to FIG. 25, a side view of a rubber object 2560 with a tab2510 is provided. A first plane 2530 is shown extending as defined byrubber object 2560. Tab 2510 extends along a plane 2540 at an obtuseangle 2550 with first plane 2530. The orientation of tab 2510 at anobtuse angle 2550 may facilitate the peeling of a rubber object 2560 outof a mold in some instances. A tab 2510 extending at an obtuse angle2550 as illustrated in the example of FIG. 25 may be formed, forexample, by providing an appropriate cavity within a mold top. Flash2590 is shown on the perimeter of the rubber object 2560.

FIGS. 26-32 use a cut-away perspective to illustrate various exemplaryconfigurations of molds that may be used to form rubber objects withtabs in accordance with aspects of the present invention. Theseillustrations are exemplary only, and other configurations andorientations of mold cavities are within the scope of the presentinvention. Further, while the present examples illustrate molds havingonly a mold bottom and a mold top, molds may be used that provideadditional components to form a molded rubber object, such as a moldside, mold rear, or mold toe.

In the example of FIG. 26, a mold bottom 2610 meets with a mold top 2615at a junction point 2650. Assembly 2600 may provide a cavity 2612corresponding to the approximate size and shape of a desired finalrubber object while a tab form 2622 extends from the cavity 2612 intothe mold top 2615. The flash channel is visible at the left end 2632 andthe right end 2634 of the flash channel.

Referring now to FIG. 27, yet a further example of a mold assembly 2700comprising a mold bottom 2710 and a mold top 2715 is illustrated.Junction point 2750 illustrates where mold bottom 2710 to mold top 2715meet. A cavity 2712 may be defined substantially within mold bottom2710, while a tab form 2722 may extend substantially, but not entirely,within mold top 2715. In the example illustrated in FIG. 27, a portionof tab form 2722 is located within mold bottom 2710, but this need notbe the case. The example mold assembly 2700 illustrated in FIG. 27 maybe used to form a rubber object having a tab extending at an acute anglerelative to the rubber object. The flash channel is visible at the leftend 2732 and the right end 2734 of the flash channel.

Referring now to FIG. 28, a mold assembly 2800 having a mold bottom 2810and a mold top 2815 meet at a junction 2850 is illustrated. A cavity2812 is contained within mold bottom 2810 while a tab form 2822 extendssubstantially perpendicular from cavity 2812 within mold top 2815. Amold such as the example illustrated in FIG. 28 may be used to form amolded rubber object having a tab extending substantially perpendicularto the molded rubber object. The flash channel is visible at the leftend 2832 and the right end 2834 of the flash channel.

Referring now to FIG. 29, a mold assembly 2900 is illustrated. A moldbottom 2910 and a mold top 2915 meet at junction point 2950. A cavity2912 may be defined within lower mold portion 2910. A tab form 2922 mayextend at an obtuse angle from cavity 2912. A mold such as illustratedin the example of FIG. 29 may be used to form a rubber object with anobtuse tab as described above. The flash channel is visible at the leftend 2932 and the right end 2934 of the flash channel.

Referring now to FIG. 30, a mold assembly 3000 comprising a mold bottom3010 and a mold top 3015 meeting at a junction 3050 is illustrated. Inthe example illustrated in FIG. 30, a cavity 3012 may be defined in themold bottom 3010. A tab form 3022 may extend from the interior of thecavity 3012 to form a molded rubber object having a tab extending fromthe interior portion of the molded rubber object. In the exampleillustrated in FIG. 30, tab form 3022 extends in a substantiallyperpendicular fashion from cavity 3012. The flash channel is visible atthe left end 3032 and the right end 3034 of the flash channel.

Referring now to FIG. 31, a mold assembly 3100 having a mold bottom 3110and a mold top 3115 is illustrated. Mold bottom 3110 and mold top 3115meet at junction 3150. A cavity 3112 may be defined within mold bottom3110 and a tab form 3122 may extend at an acute angle from cavity 3112within mold top 3115 to form a tab on a rubber object within theperimeter of the rubber object. The flash channel is visible at the leftend 3132 and the right end 3134 of the flash channel.

Referring now to FIG. 32, a mold assembly 3200 comprising a lower moldportion 3210 and an upper mold portion 3215 is illustrated. Lower moldportion 3210 and upper mold portion 3215 meet at junction 3250. A cavity3212 may be defined within mold bottom 3210, while a tab form 3222 mayextend into mold top 3215 at what will be an obtuse angle on a formedmolded object. The flash channel is visible at the left end 3232 and theright end 3234 of the flash channel.

Referring now to FIG. 33, an example method 3300 in accordance withaspects of the present invention for molding and de-molding rubberobjects is illustrated. In step 3310 a mold may be provided. The moldprovided in step 3310 may have an at least partially separable mold topand mold bottom to permit access to a cavity within the mold. The cavityaccessible by at least partially separating the mold top from the moldbottom may define a desired rubber part and may further define a tabextending from that part. The cavity and associated tab form may beprovided in one or more portion of a mold i.e., may be in a mold top, amold bottom, and/or both a top and a bottom of a mold. The tab extendingfrom the defined rubber part may extend at any angle relative to thepart and may have a thickness less than the thickness of the partitself. A tab extending from a part, as defined by a cavity provided ina mold provided in step 3310, may have a thickness of less than 20%, oreven less than 10%, of the thickness of the rubber part defined.Alternatively, the tab may have a thickness equal to the rubber part.The tab may have a thin portion at a joint between the tab's base andthe rubber part. The thin portion is included to facilitate separatingof the rubber part and the tab.

In step 3315, a rubber pellet dispenser may be positioned at a desiredlocation over the cavity in the mold, and/or the mold may be positionedat a desired location relative to the mold. The rubber pellet dispensermay have previously received rubber pellets to dispense. An X-Y table, asix-axis robotic arm or any other positioning device may be used toposition the rubber pellet dispenser in step 3315. Alternatively, therubber pellets may be distributed through the cavity, rather than atdiscrete locations.

In step 3320, a predetermined amount of rubber pellets may be dispensedat the desired location(s) in the cavity of the mold. For example, afirst predetermined amount of rubber pellets may be dispensed at a firstlocation within the cavity. The predetermined amount of rubber pelletsdispensed in step 3320 may be determined using weight, volume, elapseddispensing time, or any other means. In one aspect, it can be preferableto dispense pellets according to their weight. The amount of pelletsdispensed in step 3320 may be selected based upon the size of a cavityto be filled, the portion of a cavity to be filled, the physicalproperties of the rubber pellets, etc. Again, the pellets mayalternatively be distributed evenly through the cavity rather atdiscrete locations.

In step 3330, a computing device or other system may determine whetheradditional rubber pellets should be dispensed. If the conclusion of step3330 is that additional pellets need to be dispensed, method 3300 mayproceed to step 3335 of moving the dispenser and/or mold. If need be,additional rubber pellets may be received by the dispenser as part ofstep 3335. Method 3300 may thereafter return to step 3315 of positioningthe rubber pellet dispenser at a desired location, in this seconditeration, for example, at a second location over the cavity in themold. Subsequently, an additional predetermined amount of rubber pelletsmay be dispensed once again in a repetition of step 3320, for example asecond predetermined amount of rubber pellets. The amount of pelletsdispensed as the predetermined amount of rubber pellets may vary indifferent iterations of step 3320 based upon the location at which thosepellets are being dispensed, the object to be formed by method 3300,etc.

If the conclusion of step 3330 is that no additional pellets need bedispensed, method 3300 may proceed to step 3340 of closing the mold by,for example, securing the mold top to the mold bottom. Step 3340 maycomprise mating a mold top and a mold bottom, joining the mold top to amold bottom using a latch and/or latches, by inserting a mold within amold opening in a heat press, or through any other means.

In step 3345, heat and pressure may be applied to the mold sufficient tocause the rubber pellets within the mold to spread throughout thecavity. Step 3345 may cause the pellets to spread to fill the portionsof the cavity corresponding to the desired part and to the desired tabextending from that part.

After a predetermined amount of time and/or when desired conditions havebeen met, the mold may be opened in step 3350. Step 3350 may comprise,for example, removing the mold from a heat press, unlatching a latchsecuring a mold closed, rotating a mold top of the mold to an openposition using a hinge, etc.

In step 3355, a gripping device may be positioned over the tab formed bythe rubber filling the cavity in the mold. Step 3355 may be performed,for example, using a six-axis robotic arm or other device capable ofperforming and actuating a gripping device in three dimensions. Step3355 (of positioning a gripping device) and step 3315 (of positioning adispenser) may use the same or different mechanical systems.

In step 3360, the tab may be gripped by the gripping device. Step 3360may comprise, for example, actuating one or more sides of a grippingdevice to close over opposing sides of a tab formed by the rubberfilling the cavity in the mold. The surfaces of the gripping device maypossess textures to engage the rubber of the tab, and the grippingdevice may provide sufficient pressure for to the rubber of the tab toprevent the tab from escaping the gripping device while the grippingdevice is engaged to grip the tab.

In step 3365, the gripping device and the gripped tab may be moved awayfrom the mold bottom at a non-perpendicular angle relative to the moldbottom to peel the rubber object from the mold. The angle and force withwhich step 3365 is performed may vary based upon the size and/or shapeof a rubber object, the intricacy of any pattern formed in the rubberobject, the tackiness of the rubber object to the surface of the cavitywithin a mold, etc. Step 3365 may be performed, for example, by movingthe terminal end of a six-axis robotic arm bearing the gripping deviceat a desired angle and with a desired force relative to the mold bottomto extract the molded rubber object from the cavity of the mold.

In step 3370 the tab may be optionally removed from the rubber object.In some examples of the present invention, the tab may be useful informing a finished product incorporating the rubber object, or may atleast not be detrimental to the quality or performance of the finishedobject incorporating the molded rubber object. However, if optional step3370 is performed, it may utilize any cutting device, such as a blade,scissors, or any other cutting mechanism, to sever a tab from a rubberobject. Step 3370 may also be performed as part of a general de-flashingprocess that would otherwise be employed to remove flashing from amolded rubber object. Such de-flashing processes may involve the use ofabrasives, the tumbling of the molded rubber object within a chamber, orother mechanisms and/or processes.

Referring now to FIG. 34, a side view of a further example of a moldingsystem 3400 is provided. System 3400 and system 100 are only twoexamples of systems in accordance with aspects of the present invention,and elements of the two may be inter-changed, added, and/or omitted, inother systems that are in accordance with aspects of the presentinvention. A mold 3410 may comprise a mold bottom 3412 and a mold top3414, which may be connected by, for example, a hinge 3415. A latch 3416on mold bottom 3412 may detachably engage a ridge 3418 on mold top 3414to serve as a closure mechanism, although any type of closure mechanismmay be used. Any of a variety of molds may be used for mold 3410, andthe presence, location, configuration, and/or number of components suchas hinge 3415, latch 3416, and ridge 3418 may vary. For example, thehinge 3415, latch 3416, and/or ridge 3418 may be omitted entirely or maybe replaced with other structures in exemplary aspects. For example, itis contemplated that the mold bottom 3412 and the mold top 3414 may bemaintained physically independent of one another other than aspositioned by a heat press, in an exemplary aspect. While in an openposition, mold 3410 may expose at least a portion of a cavity 3420, andwhile in a closed position, mold 3410 may enclose the cavity 3420.

Cavity 3420 may be accessible by at least partially separating mold top3414 from mold bottom 3412 of mold 3410. Cavity 3420 may comprise a partportion 3422 corresponding to the size, shape, and other detailscorresponding to the form of a desired rubber part. Cavity 3420 mayfurther comprise a tab form 3424 extending from the part portion 3422 ofcavity 3420 into mold top 3414. Accordingly, a sufficient amount ofrubber within cavity 3420 treated with sufficient heat and/or pressureto spread through the cavity 3420 will fill both the part portion 3422and tab form 3424. Heat and pressure may be provided, for example, usinga heat press 3430, which may comprise a lower portion 3432 and an upperportion 3434 to apply heat and/or pressure to the mold bottom 3412 andmold top 3414 of mold 3410, respectively.

While a variety of mechanisms may be used to position a dispenser 3450and/or a gripping device 3460 within system 3400, in the present examplea six-axis robotic arm 3440 is illustrated. Arm 3440 may provide aterminal end 3442 that may detachably affix to tools such as a dispenser3450 and a gripping device 3460. For example, a connector 3452 may joindispenser 3450 to the terminal end 3442 of arm 3440. Similarly, grippingdevice 3460 may possess a connector 3462 that may be used to joingripping device 3460 to terminal end 3442 of arm 3440 when needed.Dispenser 3450 and gripping device 3460 may be interchanged as needed atterminal end 3442 of arm 3440 and, when not in use, may be retained on arack 3470 accessible by arm 3440. While a single arm 3440 withinterchangeable tools are illustrated in the example of FIG. 34,multiple arms, potentially with tools permanently or semi-permanentlyaffixed, may be used in aspects of the present invention.

A dispenser 3450 may dispense predetermined amounts of rubber pelletsinto the cavity 3420. The dispenser 3450 may be positionable, forexample using arm 3440, to dispense a first predetermined amount ofrubber pellets at a first location within the cavity 3420 and todispense a second predetermined amount of rubber pellets at a secondlocation within the cavity. Alternatively, the rubber pellets may bespread through the cavity 3420.

The selection of a tool for terminal end 3442 of arm 3440, thepositioning of that tool, the status of mold 3410, the use of heat press3430, and any other molding parameters may be controlled by a computingdevice 3490. For example, computing device 3490 may be operable to causearm 3440 to position an attached dispenser 3450 at a rubber pelletreservoir 3480 to receive rubber pellets 3482. Computing device 3490 maythereafter cause arm 3440 to position dispenser 3450 over at least onelocation of cavity 3420 and dispense predetermined amounts of rubberpellets at that location or locations. After dispenser 3450 hasdispensed a desired amount of rubber pellets at a desired location orlocations, computing device 3490 may close mold 3410 and secure latch3416. Thereafter, computing device 3490 may cause mold 3410 to bepositioned within heat press 3430 such that heat and/or pressure may beapplied to mold 3410. While heat press 3430 may serve as a heat source,any type of heat source that heats mold 3410 to at least a temperaturehigher than the temperature at which the rubber will be vulcanized. Forexample, ovens, induction heaters, resistive heaters, and the like maybe used as heat sources. After a predetermined amount of time haselapsed, computing device may cause mold 3410 to at least partiallyseparate to permit a molded rubber object contained within cavity 3420to be removed. In one aspect, the predetermined amount of time is thedesired vulcanization time.

In order to remove a rubber object from cavity 3420, computing device3490 may cause the terminal end 3442 of arm 3440 to move in threedimensions, as indicated by axes 3445, to return dispenser 3450 to rack3470 and to attach to gripping device 3460. Computing device 3490 maythereafter position gripping device 3460 over the tab of the rubberobject within cavity 3420 formed by tab form 3424, to grip the tab, andto extract the rubber object from the cavity 3420, as further describedbelow.

Referring now to FIG. 35, a top view of an example of an open mold 3410suitable for use in accordance with aspects of the present invention isillustrated. In the example of FIG. 35, mold 3410 has a first cavity3420 and a second cavity 3530. First cavity 3420 and second cavity 3530may correspond, for example, to a left shoe outsole and a right shoeoutsole, but may comprise any other type of part or parts of otherarticles in addition to shoes. While two cavities 3420, 3530 areillustrated in the example of FIG. 35, any number of cavities may beused in a single mold in accordance with aspects of the presentinvention. Optionally, mold top 3414 of mold 3410 may provide a furthercavity 3520 corresponding to cavity 3420 in mold bottom 3412 and afurther cavity 3535 corresponding to the second cavity 3530, althoughsuch cavities 3520, 3535 in mold top 3414 need not be provided.

As also shown in FIG. 35, a first position 3551 may have received apredetermined amount of rubber pellets from dispenser 3450 (illustratedin FIG. 34). A second location 3552, a third location 3553, and a fourthlocation 3554 may further receive predetermined amounts of rubberpellets from dispenser 3450 after dispenser 3450 has been moved by arm3440. The number, location, and position of locations within a cavity(or cavities) at which a dispenser 3450 dispenses a predetermined amountof rubber pellets may vary based upon the shape, size, and/orconfiguration of a cavity, the size, amount, tackiness, or otherproperties of the rubber pellets dispensed, or for any other reason. Inone aspect, the pellets are distributed throughout the cavity, ratherthan in discrete locations.

Referring now to FIG. 36, an example mold 3410 has received a firstpredetermined amount of rubber pellets 3651 and a second predeterminedamount of rubber pellets 3652 at a first location and a second locationwithin a cavity 3420. The amounts and locations of rubber pellets 3651,3652 illustrated in FIG. 36 are for exemplary purposes only, and may bevaried from what is shown relative to the size of cavity 3420. As shownin the example of FIG. 36, mold top 3414 of the mold 3410 is beingclosed as indicated by arrow 3601 to enclose the dispensed rubberpellets 3651, 3652 within cavity 3420 of a closed mold 3410. In thepresent example of FIG. 36, the mold top 3414 will engage the rubberpellets 3651, 3652 as mold 3410 is closed to facilitate the distributionof rubber pellets within cavity 3420 of mold 3410.

The molds illustrated herein are illustrated having features that areexemplary in nature. For example, while a hinged mold is depicted anddiscussed herein, it is contemplated that a non-hinged or physicallyindependent mold portions may be used in the alternative. For example,to get a desired degree of pressure distribution, it may be desired tohave a mold top portion that is independently moveable of a lower moldportion. Stated differently, it is contemplated that a hinge, such asthe hinge 3415 is omitted entirely in an exemplary aspect. Similarly, itis contemplated that a latching and maintaining mechanism may be omittedentirely as well. For example, the latch 3416 and the ridge 3418 may beomitted entirely in an exemplary aspect. When omitted, a press may berelied on to align the top and bottom portions of the mold as well as tomaintain the top portion and bottom portion in a mated position whilerubber is being cured, in an exemplary aspect.

Referring now to FIG. 37, a cross-section view of the mold 3410 isprovided. The mold 3410 has been closed and secured using latch 3416. Inthe example of FIG. 37, the first predetermined amount of rubber pellets3651 and the second predetermined amount of rubber pellets 3652 havebeen partially distributed within cavity 3420. The flash channel isvisible at the left end 3732 and the right end 3734 of the flashchannel.

Referring now to FIG. 38, a cross-section view of the mold 3410 and heatpress is provided. An example heat press 3430 having a lower portion3432 and an upper portion 3434 has been used to apply heat and pressureto the example mold 3410. The heat and pressure applied to mold 3410 issufficient to cause the rubber pellets to melt and spread to form arubber object 3810 that substantially fills cavity 3420, both the partportion 3422 and the tab form 3424. The heat and pressure can also besufficient for vulcanization.

Referring now to FIG. 39, a side view of the mold 3410 is provided.After a predetermined amount of time, for example, sufficient time topermit rubber object 3810 to solidify, mold 3410 may be opened asindicated by arrow 3901. Mold 3410 may be opened to permit access to thecavity 3420 for de-molding using a gripping device 3460. A grippingdevice 3460 may grip the tab formed in a rubber object after the heatsource heats the mold and the mold has been moved to an open position.The gripping device may remove the rubber object by exerting a force onthe rubber object through the tab 3924 to remove the rubber object fromthe cavity.

Referring now to FIG. 40, a top view of the mold 3410 is provided. Theopened mold 3410 is shown to provide access to a first rubber object3810 and to a second rubber object 4030. Tab 3912 extends from the firstrubber object 3810 and tab 4032 extends from the second rubber object4030.

Referring now to FIG. 41, an example gripping device 3460 has beenattached to the terminal end 3442 of arm 3440. Arm 3440 has positionedgripping device 3460 substantially over a tab 3912 formed in moldedrubber object 3810 by the tab form 3424 of the part portion 3422 withinmold 3410.

Referring now to FIG. 42, the example gripping device 3460 has beenclosed to grip tab 3912 extending from molded rubber object 3810 withinpart portion 3422 of mold bottom 3412. As shown in the example of FIG.42, arm 3440 has begun to lift terminal end 3442 and gripping device3460 away from mold bottom 3412 and, along with it, tab 3912.

Referring now to FIG. 43, the example gripping device 3460 and terminalend 3442 of arm 3440 have moved in a direction 4310 that is neitherperpendicular to nor parallel to mold bottom 3412. As a result of themotion 4310 of gripping device 3460 secured to tab 3912 of rubber object3810, rubber object 3810 has been partially separated from part portion3422.

Referring now to FIG. 44, an example molded rubber object 3810 has beencompletely removed from part portion 3422 of mold 3410. As illustratedin FIG. 44, cavity 3420, both part portion 3422 and tab form 3424, hasbeen emptied of rubber object 3810. Mold 3410 and cavity 3420 may becleaned or otherwise processed for additional molding operations, ifdesired.

Referring now to FIG. 45, a pair of rubber objects comprising a firstrubber object 4510 having a tab 4512 and a second rubber object 4530having a tab 4532 are illustrated. While any number of rubber objectsmay be formed in accordance with aspects of the present invention, theexamples of FIG. 45 are a left shoe outsole and a right shoe outsole.

Referring now to FIG. 46, an example trimming device 4610 is shown.Trimming device 4610 may be moved as indicated by arrow 4620 to severtab 4612 from rubber object 4510. In the example shown in FIG. 46,trimming device 4610 is an actuated blade, but other mechanisms may beused to remove a tab from a rubber object in accordance with the presentinvention. For example, cutting dies, reciprocating blades, scissors,abrasive de-flashing systems, or other mechanical systems may be used toremove a tab, such as tab 4512, from a rubber object such as moldedrubber object 4510. Any trimming device that removes a tab 4512 from arubber object 4510 after the rubber object 4510 is removed from a cavitymay be used.

Referring now to FIG. 47, the example trimming device 4610 has removedtab 4512 from molded rubber object 4510. In some examples, a tab such astab 4512 may not need to be removed from a rubber object such as moldedrubber object 4510 prior to incorporating the molded rubber object intoa product, such as a shoe, but in the present example the tab 4512 hasbeen removed using trimming device 4610.

The result of removing tabs 4512, 4532 from the first rubber object 4510and the second rubber object 4530 are illustrated in the example of FIG.48. The removed tabs 4512, 4532 may be recycled or disposed. The firstmolded rubber object 4510 and the second molded rubber object 4530, aswell as any additional molded rubber objects, may be incorporated into adesired product. For example, first molded rubber object 4510 may beaffixed to a mid-sole structure, a shoe upper, or other shoe componentsas part of a shoe fabrication process.

Referring now to FIG. 49, an example arm 3440 with a terminal end 3442is illustrated with a rack 3470 retaining a dispenser 3450 with aconnector 3452 and a gripping device 3460 with a connector 3462. Asshown in FIG. 49, arm 3440 may rotate 4910 to bring terminal end 3442 torack 3470 to engage a tool, such as dispenser 3450 and/or grippingdevice 3460. Additional and/or different tools may be retained by rack3470 or any similar mechanism for use by arm 3440 under the guidance ofcomputing device 3490 to execute methods in accordance with aspects ofthe present invention. For example, tools may be provided to clean amold 3410 cavity 3420; to open, close, or otherwise move a mold 3410; toexchange molds 3410 (for example to change for a different model or sizeof molded rubber objects); or for any other type of processing to formmolded rubber parts in accordance with aspects of the present invention.

Aspects of the present invention also provide methods for forming moldedrubber objects. A method may involve: dispensing at least twopredetermined amounts of rubber pellets at least two discrete locationswithin the cavity of a mold bottom; closing the mold by affixing an moldtop to a mold bottom, the mold top contacting the at least twopredetermined amounts of rubber pellets when affixed to the mold bottom;heating the closed mold to a temperature that causes the at least twopredetermined amounts of rubber pellets to spread from the discretelocations through the cavity within the closed molds, the cavitycomprising at least one tab form extending from a shape defining adesired molded rubber object, the rubber pellets combining to form anintermediate rubber object having a shape desired for a molded rubberobject and at least one tab; after a predetermined amount of time haselapsed, opening the mold by at least partially removing the mold topfrom the mold bottom; positioning a gripping device, for example agripping device on the end of a positionable mechanical arm, over thetab of the intermediate rubber object while the intermediate rubberobject remains in the mold bottom; gripping the tab of the intermediaterubber object with the gripping device; moving the gripping device andthe gripped tab of the intermediate rubber object away from the moldbottom at a non-perpendicular angle to peel the intermediate rubberobject from the mold bottom; and removing the tab from the intermediaterubber object to form a final molded rubber object.

The present invention is described above in examples only. Otherconfigurations, equipment pieces, etc. may be employed without departingfrom the scope of the present invention. While the present invention isdescribed particularly with regard to shoes and shoe components and,more particularly, with regard to rubber outsoles for shoes, other typesof rubber parts may be formed using systems and methods in accordancewith the present invention. While examples of the present invention areillustrated and described with a single tab per rubber object, multipletabs may be formed in a single rubber object, to permit a rubber objectto be de-molded in multiple steps (for example, to prevent damaging adelicate rubber object) or to provide alternatives should a particularrubber object resist de-molding using one tab.

The systems of the present invention may be controlled in accordancewith methods of the present invention by way of one or more computingdevices. Computing devices may be used in accordance with the presentinvention to execute computer readable code to cause the computer tocontrol devices and systems, such as but not limited to those describedherein, to perform the steps described herein. Computing devices maycontrol systems and/or components in accordance with the presentinvention via connections, both wireless and wired, through networkconnections, etc. Computing devices and computer readable code retainedin memory thereon or accessible thereby may be adaptable for differenttypes of molded objects and/or different sizes or numbers of moldedrubber objects. For example, a computing system executing computerreadable code to perform methods in accordance with the presentinvention may cause different amounts of rubber pellets to be dispensedat different locations for different products, different sizes ofproducts, etc. In this fashion, systems and methods in accordance withthe present invention may readily process different sizes of shoe parts,different models of shoes, or even different products entirely.

Having thus described the invention, what is claimed is:
 1. A system forforming molded rubber objects, the system comprising: a mold having amold top and a mold bottom that together define an exterior of a cavitythat defines a size and shape of a molded rubber object and a tab formthat defines a size and shape of a removable tab extending from themolded rubber object, the tab form located, at least in part, in themold top, the mold capable of being in at least an open position thatexposes at least a portion of the cavity and a closed position thatencloses the cavity within the mold; a dispenser that dispensespredetermined amounts of rubber pellets into the cavity; a heat sourcethat heats the mold to at least a temperature and pressure at whichvulcanization of the rubber pellets occurs; and an arm having a clawthat grips the removable tab formed with the molded rubber object afterthe mold has been moved to the open position, the arm exerting a forceon the molded rubber object through the removable tab to remove themolded rubber object from the mold.
 2. The system of claim 1, whereinthe dispenser is positionable to dispense a first predetermined amountof pellets at a first location within the cavity and a secondpredetermined amount of pellets at a second location within the cavity.3. The system of claim 2, wherein the dispenser dispenses the firstpredetermined amount of pellets and the second predetermined amount ofpellets based upon weight.
 4. The system of claim 1, wherein the systemfurther comprises a trimming device that removes the removable tab fromthe molded rubber object after the molded rubber object is removed fromthe cavity.
 5. The system of claim 4, wherein the mold provides the tabform such that the removable tab is integrally formed with and extendingfrom flashing on an edge of the molded rubber object.
 6. The system ofclaim 5, wherein the trimming device that removes the removable tab fromthe molded rubber object comprises a deflashing system that removesflashing from the molded rubber object while removing the removable tab.7. A method for forming molded rubber objects, the method comprising:dispensing rubber pellets within a mold bottom; closing the mold bybringing a mold top together with the mold bottom to define an exteriorof a cavity and a tab form within the mold, the cavity defining a sizeand shape of a molded rubber object, and the tab form defining a sizeand shape of a removable tab extending from the molded rubber object,the tab form located, at least in part, in the removable mold top;heating the closed mold to a temperature at which vulcanization of therubber pellets occurs, the rubber pellets forming an intermediate rubberobject having substantially the size and shape of the molded rubberobject and the removable tab; after a predetermined amount of time haselapsed, opening the mold by at least partially removing the mold topfrom the mold bottom; gripping the removable tab of the intermediaterubber object with an arm having a claw while the intermediate rubberobject remains in the mold bottom; moving the arm and the removable tabof the intermediate rubber object away from the mold bottom to separatethe intermediate rubber object from the mold bottom; and removing theremovable tab from the intermediate rubber object to form a final moldedrubber object.
 8. The method of claim 7, further comprising removingflashing from the intermediate rubber object while removing theremovable tab.
 9. The method of claim 7, wherein the removable tabextends substantially perpendicular to the mold bottom.
 10. A system forforming molded rubber objects, the system comprising: a heat pressstation having a mold opening adapted to receive a mold and apply heatand pressure to the mold; the mold having a mold top and a mold bottomthat together define an exterior of a cavity that defines a size andshape of a molded rubber object and a tab form that defines a size andshape of a removable tab extending from the molded rubber object, thetab form located, at least in part, in the mold top, the mold capable ofbeing in at least an open position that exposes at least a portion ofthe cavity and a closed position that encloses the cavity within themold; a dispenser that dispenses at least one predetermined amount ofrubber pellets into the cavity when the mold is in the open position;and an arm having a claw adapted to grip the removable tab formed in themolded rubber object after the mold has been moved to the open position,the arm exerting a force on the molded rubber object through theremovable tab to remove the molded rubber object from the cavity. 11.The system of claim 10, wherein the removable tab extends from flashingattached to a perimeter of the molded rubber object.
 12. The system ofclaim 10, wherein the heat press station has a heat source that heatsthe mold in the closed position to at least a temperature at whichvulcanization of the rubber pellets occurs.
 13. The system of claim 10,wherein the arm is an articulated arm that can access multiple heatpress stations.
 14. The system of claim 10, wherein the dispensercomprises at least two cups, which are pre-filled with the at least onepredetermined amount of rubber pellets, that dispense the rubber pelletsinto the cavity.
 15. The system of claim 14, wherein a first of the atleast two cups dispenses the rubber pellets at first location within thecavity and a second of the at least two cups dispenses the rubberpellets at a second location within a second independent portion of thecavity that is different from the first location.
 16. The system ofclaim 10, wherein the cavity defines a perimeter of the molded rubberobject and the removable tab extends beyond the perimeter.
 17. Thesystem of claim 10, wherein the tab form extends from a junction of themold top and the mold bottom.
 18. The system of claim 10, furthercomprising an X-Y table that positions the dispenser.
 19. The system ofclaim 18, wherein the dispenser dispenses a first predetermined amountof rubber pellets into the cavity at a first location and dispenses asecond predetermined amount of rubber pellets into the cavity at asecond location, the first location is different from the secondlocation and the first predetermined amount is different from the secondpredetermined amount.
 20. The system of claim 19, further comprising adeflashing station for removal of flash and the removable tab from themolded rubber object.